There is actually nothing wierd going on at all.
When you launch the VST it communicates to Sonar what its audio outputs are... if you have the kontakt default VST audio outs it will tell sonar its got st1, aux1-4 and unassigned x-y...
What i stated above was simply to change the outputs and save them as defaults, and consider me wierd but if i want an 8 ch stereo plug i will have them called st1-st8 :)
So, having changed the default for the 8 ch versions of Kontakt this simply wont happen again.. when the vst is loaded, it will communicate to sonar it has 8 stereo outs....
regards, Ian